Roof construction



April 19, 1960 E. MARTIN ROOF CONSTRUCTION 2 Sheets-Sheet 1 Filed Nov. 15, 1954 IN V EN TOR.

ATT'YS April 19, 1960 E. MARTIN ROOF CONSTRUCTION Filed NOV. 15, 1954 2 Sheets-Sheet 2 INVENTOR: EDWARD MARTIN ATT'YS 2,933,056 ROOF CONSTRUCTION Edward Martin, Chicago, Ill., assignor to M.P.H. Manufacturing Corp. Inc, Chicago, III., a corporation of Illinois Application November 15, 1954, Serial No. 468,77?

Elairns. (Cl. ros -is This invention relates to a construction for a roof or the like and is particularly concerned with a structural panel or member and method of manufacture, and a roof or roof section constructed of a plurality of panels.

In the building of a trussless roof, for example, name- 1y, that type characterized by an absence of trusses and supports distributed over the building area, and in which the roof is so contoured as to enable it to be supported directly on the foundation, it is highly important that great rigidity and strength be inherent therein. The absence of trusses, cross-braces and columns gives rise to problems which must be solved in the design of the panels or sections comprising the roof, and embracing the factors of lateral and longitudinal thrust and direct loading.

It had been proposed previously, in US. Patent No. 2,436,543, patented February 24, 1948, to John F. Blaski, to provide a metallic roof or ceiling structural panel having a transverse cross section which is substantially trough-shaped, the trough portion of the panel being transversely corrugated to arch the member longitudinally. This construction provided a longitudinally arcuate panel conforming to the transverse curvature of the roof and characterized by favorable strength and rigidity.

A principal object of the present invention is to provide improvements in roof construction, and in the preferred construction, to provide further improvements in the panel described in the patent. Thus, in a roof assembly composed of a plurality of interconnected troughshaped panels according to the patent, there may be a certain amount of transverse extensibility or compressibility resulting from the cross-sectional configuration of the panels. One object of the invention is to secure the panels against such alterations.

At the same time, the invention provides a construction for protecting or shielding the panels against accumulations of Water, dirt and debris in the troughs. The roof is also protected against penetration of water, dust and so forth, between the panels, into the covered or enclosed area.

Another object is to provide in a structural panel the features of rigidity and strength afforded by the foregoing trough construction while extending the amount of coverage provided by a panel constructed from a given amount of metal. While the maximum strength is present in a roof construction when the greatest number of troughs is employed, forming a corresponding number of arches, it is apparent that this also requires a considerable quantity of material to form the troughs covering a given area. The preferred panel of the invention, therefore, includes a trough portion providing the aforesaid advantages and an adjoining wide flange portion serving to extend the coverage of a panel while retaining the necessary strength.

it is another object to provide a panel which is bent or deformed for interlocking with an adjacent panel to hold them against relative lateral movement. In a preferred form of the invention, the deformations serving to fix the relative positions of the panels also serve to provide increased structural strength.

2,933,055 ?at ented Apr. 19, 19 60 A further object is to provide a structural panel adapted for overlapping engagement with adjacent panels and provided with means for rapidly and efiectively securing them together in a strongand tight manner.

It is another object to provide a new and improved method of forming a structural panel from a flat blank or sheet.

An additional object is to furnish a roof section constructed of a plurality of the new structural panels and requiring no trusses and supports, but capable of being emplaced on a simple foundation and withstanding high loads and stresses.

Still another object is the provision of a unitary or single-piece structural panel having the component structural portions formed therein, and the invention also has to do with the construction and arrangement of the panel and its components; These and other objects, functions and advantages of the invention will appear on consideration of the specification taken in conjunction with the accompanying drawings of preferred embodiments of the invention, in which like parts are identified by like reference characters in each of the views, and in which:

Figure l is a perspective view of a building embodying the new roof construction;

Figure 2 is a topperspective view of one embodiment of the panel of the invention; V

Figure 3 is a top perspective view of another embodiment of the panel;

or the like;

Figure 5 is a top plan view of the panel of Figure 3;

Figure 6 is an enlarged side elevational view of the panels of Figures 3-5 and 7, particularly illustrating the trough portion and the corrugations therein; and

Figure 7 is a top perspective View of still another embodiment of the panel.

In accordance with the invention, a structural panel adapted for use in multiple in a roof or the like is provided which includes a unitary longitudinally arcuate member provided with a longitudinal trough portion and an adjoining laterally extending longitudinal flange portion adapted to cover a like trough portion of an adjacent panel, and a plurality of corrugations extending transversely of the trough portion to arch the member longitudinally. The flange portion has a width at least as great as that of the mouth or open side of the trough portion, to cover the adjacent trough portion. In the preferred form of the invention, the depth or amplitude of the corrugations is a maximum at the base or bottom of the trough and decreases along the sides of a trough to a minimum adjacent the mouth of the trough.

- The flange portion preferably has a width substantially greater than that of the trough portion, to provide a substantial distance between laterally adjacent troughs with the flange portion yet covering the trough portion of an adjacent panel. The construction thus provides the advantages of the trough construction, the overlapping and securing of a trough portion by an adjacent flange portion, and the extension of the coverage provided by a panel. The part of the flange portion situated between laterally adjacent trough portions is preferably corrugated transversely, to impart additional strength.

A plurality of longitudinally spaced holes is provided in the panel for connecting adjacent panels in a strong and rigid roof construction. It is also very advantageous to provide a deformation in the panel for engagement with an adjacent panel to interlock the panels and hold them against relative lateral movement. Preferably, longitudinal raised portions are provided adjacent the trough assaoss .vided on an adjacent panel. It is also preferred that the spaced holes be located in the raised portions.

A method is provided in which two opposed lateral portions of a flat blank or sheet are bent to provide a longitudinal trough portion and an adjoining lateral extending substantially flat longitudinal flange portion therein, and the trough portion is corrugated transversely to .arch it and the panel'longitudinally. The resulting flange portion is adapted to cover the trough portion of a laterally adjacent panel, preferably with the adjacent trough portions spaced -by a part'of the flange portion. The blank is deformed for interlocking the panel with an adjacent panel. Preferably, the part of the flange portion separating the adjacent trough portio'ns is transversely corrugated with'corrugations of substantially uniform depth. r

In the drawings, one embodiment of the invention is illustrated in Figure 2, which illustrates a unitary longitudinally arcuate panel or construction unit or piece 1 formed from a single sheet or relatively thin blank, which is preferably of sheet steel and which may be galvanized. Similar panels representing other embodiments of the invention are illustrated in Figures 3-7 and are identified by the reference numerals 1a and 1b. The panel 1, and the other panels, is longitudinally curved or arched in any'desired curvature and may correspond to the arc of a circle, as shown, or to an arc of an ellipse, or it may be otherwise curved. The panel is thus made to confo'rm to the transverse curvature of a roof or roof section, as illustrated in Figure 1 by the trussless roof 2 of a building 3. A complete building of this type is constructed simply by erecting the roof 2 on a simple foundation and completing the enclosure, if desired, with bulkheads or end walls 4.

'Each'panel 1 1a orlb, includes a longitudinally arcuate trough portion 5 and'a generally flat adjoining laterally extending longitudinal flange portion 6, 6a or 6b. The trough or channel portion- 5 is in depending position in normal use in a roof and is provided with a plurality of continuous corrugations 7 extending uninterruptedly over the entire length of the trough portion. The trough corrugations 7 serve to longitudinally arch the trough portion 5 and at the same time provide the same curvature in the remainder of the panel. The trough corrugations are preferably provided as described in the above referred to patent to Blaski, that is, the depth of the corrugations, or of the grooves 8 (see Figure 6), is a maximum at the base or bottom 9 of the trough portion 5, and .the corrugations decrease in depth from the base along the sides 12 and 13 of the trough portion to a minimum adjacent the mouth 10 or open side of the trough, defined by the longitudinal edges or lateral extremities ll'and 11a of the trough portion 5. It is preferred that the corrugations terminate in the sides 12 y and 13 of thetrough portion, short of its longitudinal edges or upper extremities, to leave relatively narrow or short flat zones 14 and 15 between the edges 11 and 11a and the corrugations 7 in the sides. As described in the patent, the corrugations 7 are most advantageously continuous over the base or bottom 9 of the trough portion 5 and over the major portion of the sides 12 and 13 of the trough portion, with the corrugations disposed transversely of the longer axis of the panel 1, 1a or 1b. 'Any longitudinal plane passing through the corrugations in the trough portion perpendicularto its surface intersects all the corrugations to form a sine curve. corresponding to the formula y=r sin x where:

y is the ordinatemeasured from the axis of at for any point of the curve d r is the amplitude and x is the abscissa of the point.

At the longitudinal axis of the base 9 of the trough portion 5, r is a maximum. From the base, 1' gradually and evenly diminishes up each side 12 and 13, reaching zero adjacent the longitudinal edges 11 and 11a, at the flat zones 14 and 15 where the corrugations end. The selection of a sine curve for the cross-sectional contour of the corrugations permits their reduction in depth from a maximum at the base 9 of the trough portion 5 to zero in its sides 12 and 13 with a linear decrease of stress absorption.

In the form illustrated, the trough portion 5 is substantially V-shaped. However, the trough portion may be given other cross-sectional configurations, such as U-shaped or corresponding to the arc of a circle. It will be noted that a trough portion in one of these configurations is susceptible to transverse compressibility or extensibility by applying pressure or tension to its lateral extremities. This is obviated in the present invention by the interlocking and overlapping assembly, as will appear. Also, the trough portion is inclined to collect water and debris, and the construction providing for overlapping covers the trough portion to prevent this.

In the simplest form of the invention, as illustrated in Figure 1, the flange portion 6 adjoining the trough portion 5 may be smooth, corresponding to the initial sheet. It has a width at least as great asthe mouth it of the trough and is adapted to cover a trough portion of an adjacent panel, in a similar manner to that illustrated in Figure 4, the part, 16 of the flange portion 6 which. is remote from the trough portion and is adjacent one longitudinal edge 17 of the panel serving as the overlapping portion. The width of the flange portion 6 is sufliciently great ,to space the adjacent trough portion of an adjacent panel laterally a substantial distancefrom the trough portion 5. Thus, there is provided between the overlapping portion 16 and the trough portion 5 an intermediate flange portion 18 which extends the coverage of the, panel and serves to space the trough portions while retaining the structural advantages of the trough portions and. the necessary strength in the roof construction. The flange portion 6 is longitudinally coterrninus with the trough portion 5. I

Rows of longitudinally spaced holes or apertures 19 and 20 are provided on either side of the trough portion 5 along its sides 12 and 13. Additional rows of longitudinally spaced holes 21 and 22 are provided in the overlapping portion 16 of the flange portion, and they correspond respectively with the holes 19 and 2 0. The holes in the overlapping portion are arranged to register with holes along the trough portion like 19 and 20 provided on a laterally adjacent panel, and the, holes are preferably spaced equidistantly for registering when the panels are in staggered side by side relation. The panels are secured in side by side relation by inserting bolts, such as 23 in Figure 4, through the pairs of. holes and securing the bolts. The panels are also overlapped in end to'end relation, with upperpanels overlapping lower panels, as illustrated in Figure 1. For this purpose, the end holes 19, 20, 21 and 22 may be caused to register with those on a longitudinally adjacent panel for securing the ends of the panels together, if desired. 7 Also, the ends of the panels, including those of the trough portions 5, may be left free of corrugations for'overlapping purposes if desired. It will be apparent that variations in the constructions and arrangements illustrated may be made within the purview of the invention. Thus, the holes 19 and 20 might be provided instead in the upper parts of the sides 12 and 13 of the trough portion 5, the overlapping portion being constructed accordingly.

In the arrangement illustrated in Figure 1, the flat overlapping portion 16 spans the mouth 10 of an adjacent trough portion 5, and the overlapping portion is con- -nected to the adjacent panel on either side of the trough portion by means of the several holes and securing means such as bolts 23. The trough portion is then braced against any lateral movement of its sides. At the same time, a strong and rigid roof section constructed of a plurality of panels results, since the roof section is composed of a number of arches represented by the trough portions which are joined by the flange portions 6. The intermediate portions 18 of the flange portions are continuous with the overlapping portions 16, and the overlapping portions are securely connected to adjacent panels, so that the intermediate portions 13 are rigid and strong, and there is no weakness introduced in their connection to adjacent trough portions. A lip or narrow flange 23, one edge 24 of which is the other longitudinal edge of the panel, is provided on the side of the trough portion 5 which is remote from the flange portion 6. This lip, adjoining the trough portion 5 along one longitudinal edge 11 thereof, is provided with the above referred to spaced holes 19 and serves to support the overlapping portion 16 while providing means for connecting the panels.

Figures 3-5 illustrate a panel 1a provided with deformations, raised portions or beads for engaging adjacent panels and strengthening them. Longitudinal raised portions 25 and 26 are formed on either side of the trough portion 5 and spaced at short distance from its longitudinal edges 11 and 11a. Holes 19a and 20a, corresponding to holes 19 and 20 of panel 1, are formed in the raised portions 25 and 26. As illustrated in Figure 4, a longitudinal angular construction corresponding to angles 27, 28, 27a and 28a results from the deformations 25 and 26 in the lip 23a and in the flange portion 6a, respectively, which are laterally spaced from the trough portion 5. This angular construction furnishes increased structural strength in the longitudinal direction and is preferred to a construction wherein this feature is omitted,

such as where the raised portions 25 and 26 terminate in the longitudinal edges 11 and 11a of the trough portion instead of being spaced from the edges.

A pair of raised longiudinal portions 29 and is provided in the flange portion 6a in an overlapping portion 16a thereof. The overlapping portion is separated from the trough portion 5 by an intermediate flange portion 18a, lying between the inner raised portion 26 adjacent the trough portion and the inner raised portion 29 in the overlapping portion. Holes 21a and 22a are provided in the raised portions 29 and 3t These raised portions correspond respectively to the raised portions 25 and 26 adjacent the trough portion in configuration and arrangement, and they are constructed to overlap portions like the latter provided on an adjacent panel with the holes 21a and 22a registering respectively with holes like 19a and 20a on the adjacent panel for connectthe panels, as illustrated in Figure 4. The several raised portions are illustrated as being generally V-shaped but may be otherwise contoured. This constnuction provides interlocking of the panels and holds them against relative lateral movement. It will be apparent that other configurations and arrangements within the spirit and scope of the invention would serve to furnish the desired results and accomplish the objects of the invention.

The intermediate portion 18a of the flange portion 6a spaces the adjacent trough portions 5 a substantial distance laterally, as in the embodiment of Figure 2, so as to extend the coverage of the panel while retaining the necessary structural strength. Thus, for example, the distance B between centers of the two innermost raised portions 26 and 29, illustrated in Figure 4, may be about 18 inches, with the distance A between centers of the pairs of raised portions 25 and Z5, and 29 and being about 6 inches and the distance C representing the depth of the trough being about 4 inches. In a preferred construction, the intermediate portion 18a is up to about 3-4 times as wide as the mouth 16 of the trough :portion.

Theflange portion 6a excluding the overlapping portion 16a is of the same order of magnitude and is slightly Wider to provide for the raised portion 26.

A further embodiment providing increased structural strength is illustrated in Figure 7. The panel 1b has a plurality of continuous corrugations 31 of substantially uniform depth extending transversely of an intermediate portion 18b of the flange portion 6]), providing a corrugated portion in the flange portion, and the panel otherwise corresponds to that of Figures 3-5. These corrugations likewise extend for the length of the panel, and they extend transversely to points adjacent the innermost bead portions, 26 and 29, formed on the flange portion 6b. in this manner, the part of the flange portion intermediate two adjacent trough portions, when assembled, is strengthened while retaining the substantially flat charactor of the arched flange portion. The corrugations 31 in the corrugated portion 18b can also terminate short of the ends of the panel to provide for overlapping, or they and the corrugations 9 of the trough portion can be nested in those of a longitudinally adjacent panel.

The panels 1, 1a or 1b may be assembled in a trussless roof construction 2, as illustrated in Figure 1, by forming arched sections of panels32, consisting of a plurality of panels in overlapping end to end relation with the upper panels overlapping the lower panels. Laterally adjacent panels in adjacent sections or rows 32 are engaged in overlapping side by side relation, with the overlapping portions 16, 16a or 16b overlying adjacent trough portions 5 and with the raised portions 25, 26, 29 and 30 nesting or engaging, where provided, and also with the corresponding longitudinally spaced bolt holes in register. On inserting and securing bolts in the holes, the panels and sections are securely joined. The panels in adjacent rows are preferably staggered, panels of half-length being employed where necessary. The trough portion 5 which is uncovered at one end of the building 3 can be covered by a suitable strip of metal, or can be braced with metal strap, as desired. The roof is erected on, for example, concrete foundations which are located along the longitudinal edges of the building, corresponding to the ends of the bottom panels. The building or enclosure may be used as such, or it may be completed with bulkheads 4 at the ends.

The new roof construction is characterized by great rigidity and strength, supporting and resisting large loads and stresses, including lateral and longitudinal thrust and direct loading. No trusses or supports are required, so that the available interior space is a maximum and constructional labor and cost are greatly reduced. The roof construction is fixed against lateral extension or compression. Extensive coverage is provided by the panels in relation to the amount of material required. The trough portions serving as structural arches are covered and protectedfrom accumulations of moisture and debris,

and the roof sheds water and dirt and prevents their entry at the junctures of the panels.

The invention is hereby claimed as follows:

1. A structural panel adapted for use in multiple in a roof or the like comprising a unitary longitudinally arcuate member provided with a longitudinal trough portion and an adjoining laterally extending longitudinal flange portion adapted to cover a like trough portion of an adjacent panel, a plurality of corrugations extending transversely of said trough portion to arch said member longitudinally, a plurality of holes spaced longitudinally of said member along each side of said trough portion, and a corresponding plurality of spaced holes in said flange portion arranged to register with an arrangement of holes like the former along each side of said trough portion in said adjacent panel.

2. A structural panel adapted for use in multiple in a roof or the like comprising a unitary longitudinally arcuate member provided with a longitudinal trough portion and an adjoining laterally extending longitudinal 7 flange portion adapted to cover a like trough portion of an adjacent panel, a plurality of corrugations extending transversely of said trough portion to arch said member longitudinally, a longitudinal deformation in said member adjacent said trough portion, and a like deformation in said flange portion adapted with the longitudinal deformation adjacent said trough portion of said adjacent panel to hold the panels against relative lateral movement.

3. A structural panel adapted for use in'multiple in a roof or the like comprising a unitary longitudinally arcuate member including a longitudinal substantially V-shaped trough portion adjacent one longitudinal edge thereof, and an adjoining longitudinal flange portion extending'laterally from the edge of: said trough portion remote from said longitudinal edge, a part of said flange portion lying adjacent the other longitudinal edge of said member being adapted to cover a like trough portion of an adjacent panel, a plurality of transverse corrugations in said trough portion and arching said member longitudinally, and a plurality of transverse corrugations in said flange portion extending between said trough portion and said part of said flange portion.

4. A structural panel adapted for use in multiple in a roof or the like comprising a unitary longitudinally arcuate member including a longitudinal V-shaped trough portion adjacent one longitudinal edge thereof and an adjoining laterally extending longitudinal flange portion including successively a raised portion, a corrugated portion and an overlapping portion, said trough portion being corrugated transversely to arch said member longiturdinally, said'raised portion being a longitudinal deformation in said flange portion adjacent said trough portion, said corrugated portion including a plurality of, transverse corrugations, said overlapping portion lying adjacent the other longitudinal edge of the member and being adapted to cover a like trough portion of an adjacent panel and also including a longitudinal deformation adapted for engagement with a like raised portion on the adjacent panel.

. 5. A structural panel adapted for use in multiple in a roof or the like comprising a unitary longitudinally arcuate member including a longitudinal ii-shaped trough portion adjacent one longitudinal edge thereof and an adjoining laterally extending longitudinal flange portion including successively a raised portion, a corrugated portion and an overlapping portion, said trough portion being corrugated transversely to arch said member longitudinally, said raised portion being a longitudinal deformation in said flange portion adjacent said trough portion, said corrugated portion including a plurality of transverse corrugations of substantially uniform depth, said overlapping portion lying adjacent the other longitudinal edge of the member and being adapted to cover a like troughportion of an adjacent panel, said member being provided with a plurality of longitudinally spaced holes along the first-named longitudinal edgethereof, said raised portion being provided with a plurality of holes spaced therealong, said overlapping portion being provided with a plurality of spaced holes corresponding in arrangement to the first-named plurality of holes, said overlapping portion including a longitudinal deformation providing a raised portion corresponding to the first-named raised portion and having a plurality of spaced holes corresponding in arrangement to the secondnamed plurality of holes, said member being thereby adapted for engagement with said adjacent panel with holes like the'first and second-named pluralities of holes in the adjacent panel registering with the respective said corresponding pluralities of holes and with the secondnamed raised portion overlying a raised portion like the first-narnel raised portion in the adjacent panel.

6. A structural'panel adapted for use in multiple in a roof or the like comprising a unitary longitudinally arcuate member provided with a longitudinal trough por tion and an adjoining laterally extending longitudinal flange portion adapted to cover a like trough portion of an adjacent panel, a plurality of corrugations extending transversely of said trough portion to arch said member longitudinally, a longitudinal raised portion along and adjacent each side of said trough portion and spaced therefrom, a plurality of longitudinally spacedholes in each said raised portion, and a pair of longitudinal raised portions and spaced holes therein in said flange portion corresponding to the first-named raised portions and holes therein adapted for engagement with said adjacent panel with the raised portions in the flange portion engaging raised portions like the first-named raised portions in the adjacent panel and with the holes in the engaging raised portions in register.

7. A structural panel adapted for use in multiple in a roof or the like comprising a sheet bent to form a longitudinal trough portion and an adjoining laterally extending longitudinal flange portion adapted to cover a like trough portion of an adjacent panel, the width of said flange portion being sufficiently great to space said adjacent trough portion laterally a substantial distance from the first-named trough portion with said flange portion covering the adjacent trough portion, and a plurality of corrugations extending transversely of said trough portion, the depth of said corrugations being a maximum at the base of the trough and decreasing along the sides of the trough to a minimum depth adjacent the mouth thereof, whereby said panel is longitudinally arched.

8. A structural panel adapted for use in multiple in a roof or the like comprising a sheet bent to form a longitudinal trough portion and an adjoining laterally extending longitudinal flange portion adapted to cover and be secured to a like trough portion of an adjacent panel, a plurality of;corrugations extending transversely of said trough portion, the depth of said corrugations being a maximum at the base of thetrough and decreasing along the sides of the trough to a minimum depth adjacent the mouth thereof, whereby said panel is longitudinally arched, a pluralityof corrugations of substantially uniform depth extending transversely of said flange portion, a longitudinal deformation in said sheet adjacent said trough portion, and a like deformation in said flange portion adapted to interlock with the longitudinal deformation adjacent said trough portion of said adjacent panel to hold the panels against relative lateral movement.

9. A structural panel adapted for use in multiple in a roof or the like comprising a sheet bent to form a longitudinal trough portion and an adjoining laterally extending longitudinal flange portion adapted to cover a like trough portion of an adjacent panel, a plurality of corrugations extending transversely of said trough portion, the depth of said corrugations being a maximum at the base of the trough and decreasing along the sides of the trough to a minimum. depth adjacent the mouth thereof, whereby said panel is longitudinally arched, a longitudinal raised portion along each side of said trough portion and adjacent thereto, and a corresponding pair of longitudinal raised portions in said flange portion adapted to engage raised portions like the former in said adjacent panel.

10. A roof section constructed of a plurality of panels according to claim 6 disposed in end to end and side by side relation with the panels overlapping laterally adjacent panels and covering the trough portions of the latter.

References Cited in the tile of this patent UNITED STATES PATENTS Re. 19,880 Little Mar. 3, 1936 1,940,830 Weyerbacher Dec. 26, 1933 2,153,119 Kahn et a1 Apr. 4, 1939 2,812,730 Hermann Nov. 12, 1957 OTHER REFERENCES Wonder Building, pp. 41 and 42 M. P. H. Mfg. Corp., Chicago, 111. i 

